Material for lining canals and ditches



1386- 1964 c. G. CASH ETAL MATERIAL FOR LINING CANALS AND amass FiledDec. 19. 1960 INVENTOR5 Wlieril.

ATTORNEY United States Patent Ofiice Patented Dec. 8, 1964 MATERIAL FGRLliNlNG CANAL AND DITCl-ES Carl G. Cash, Whippany, Arnold J. Hoiberg,Montville,

and Walter L. Butterfield, Whippany, N-IL, assignors,

by mesne assignments, to The Flintlrote Company, a

corporation of Massachusetts Filed Dec. 19, 1960, Ser. No. 76,911Claims. (Cl. 117-25) This invention relates to material for use inlining canals and ditches, particularly such as employed in waterconservation systems.

In such systems, wherein irrigation canals and ditches are utilized forconveying water, it is essential that the surface of the canal or ditchbe treated so as to prevent loss of water by drainage or seepage whichwould other- 7 vide a canal or ditch liner material in the form of aflexible sheet material which can be supplied in the form form ofconvoluted rolls thereof to the job site and from which the material maythere be readily unrolled and applied as an exposed membrane to serve asa heavy duty lining for ponds, canals, reservoirs and irrigationditches.

Another object of the invention is to provide for such purposes, a sheetmaterial of the character described, and

' exhibiting a high degree of flexibility both on aging and over aconsiderable temperature range, high bursting strength propertiessufficient to resist mechanical injury in service, adequateweatheringability, and the ability to be manufactured and handled withoutcracking.

Still another object of the invention is to provide a material of thecharacter and for the purposes set forth, which can be fabricated atrelatively low cost and which can readily be installed asa canal orditch liner without requiring the use of special equipment such asrequired for installing cement concrete lining, and without requiringthe use of skilled labor.

Briefly stated, the canal or ditch liner material of the presentinvention is composed of a base of woven jute fiber treated so as torender it rot-proof and substantially free from attack by microorganismswhen in contact with soil and water. The woven jute base is saturatedwith asphalt of a softening point (R. & B.) 135 to 16071 and otherphysical characteristics as hereinafter set forth. In accordance withthe invention, the saturated sheet of woven jute fiber is coated on eachof its surfaces with a layer of asphalt having a softening point,penetration and ductility characteristics hereinafter more particularlyset forth and stabilized by incorporating therein, in an amount I offrom about 25 to 4 5% by weight, finely divided minferal particles, suchas traprock, of a mesh size such that at least by weight thereof passesa 200 mesh screen. Moreover, in respect of the asphalt component of thecoating layers, it is essential that this be air-blown in the presenceof a catalytic agent selected from the group consisting of phosphoruspentoxide, red phosphorus, phosphoric acid, and stable sulfides ofphosphorus, such as phosphorus sesquisulfide, phosphorus sulfide'andphosphorus pentasulfide.

So-called catalytic asphalts produced by air-blowing high molecularweight-petroleum hydrocarbons in the presence of various in organicsalts are well known. We have found, however, that in order to provide amembrane capable of serving as a liner for canals or ditches as hereinset forth, and which will have the required'fiexibility at lowtemperatures, the required high temperature resistance to flow of thecoating layers, as Well as the,

ability to be manufactured and handled without cracking of the coating,it is essential that the asphalt component of the coating layers be anair-blown asphalt produced by air-blowing in the presence of a stablephosphorus catalyst, such as the phosphorus compounds above mentioned.Ordinary straight blown asphalts, even though possessing the softeningpoint and penetration characteristics herein referred to do not possessthe ductility characteristic which is an essential property of theasphalt component of the coating for the jute fiber base in order torender it capable of serving as a canal or ditch liner. For thatpurpose, the asphalt of the coating layers should have a minimumductility of 3.5 centimeters at 77 F. Thisrelatively high ductility isessential in accordance with the'invention in order that the asphalt becapable of accommodating itself to the stretch of the jute fiber base inmanufacture; arid service. if

Likewise, we have found that asphalts which are produced by air blowingin the presence of other catalysts, such as iron chlorides or othercompounds or iron, zinc chloride, and aluminum chloride, are noteffective or capable of serving'for thecoating of the jiite fiber baseto be used as canal or ditch liner material, owing to the fact that suchasphalts lack the, required heat stability and are also inferior intheir weathering properties.

Accordingly, the asphalt component ofthefcoating layers for the base maybe produced as described in Patent No. 2,450,756, granted October 5,1948 to one of the present applicants. As stated briefly above, thecoating asphalt is" filled,

i.e. uniformly combined with a mineral stabilizer, such as finelydivided traprock having a screen grading showing sive convolutionswhenthe sheet is rolled up, and pre I vents age-hardening in storage, suchas 'would cause cracking of the coating during handling, especially atlow atmospheric temperatures. j The thus coated base may be dusted onboth surfaces with a layer of mica or talc in those instances where it vis desired that the camel liner be relatively smooth, the

mica or talc serving also to provide additional protection againststricking of the convolutions when the product is in the form of rolls.In those instances where the canal or ditch liner is to be used underconditions requiring increased Weather-resistant properties, the coatinglayer on one side of the membrane may be provided with a layer ofmineral granules, such as oiled traprock granules of a grading known asNo. 11 roofing granules, this grading being such that essentially allare of a size to pass an 8 mesh and to be retained on a 35 mesh sieve.Desirably, when one surface of the membrane isthus provided with a layerof mineral granules of thecharacter described, this surfaceis alsoprovided with a selvage edge, of saytwo inches width, over whichrelatively fine sand is applied as a surfacing, in order to enableoverlapping margins of the membrane, when applied on the job, to besealed as by application of heat or suitable mastic adhesive.

Referring more in detail to the liner material of the invention in itsactual embodimentsthe jutefabric utilized asthe base may be burlap,which is a plain woven fabric weighing 7 to 12' ounces per lineal .yard,or sacking, which is'made from lower grades of fibers and which'is arela= tively heavy, loosely woven cloth, weighing from 12 to 15' ouncesper lineal yard (based, in each instance, on a 40 inch width). 7 Morespecifically, for example, there may be employed a jute fiber sacking ofx 8 weave, weighing ounces per lineal yard of 40 inchwidth and known in4 (R. & B.) of from 135 to 160 F. and further characterized by thefollowing physical properties:

Penetration at: i

. 77 F., 100 g./5,s'ec., min/10 -100. 32 F., 200 g./ sec., mm./l0' 15min. .F., 50 g./5 sec., man/l0 150 max. Flash point, Cleveland O.C. 475F., min. Ductility at 77 F.,' 5 cm. per minute 3 /2 cm. Viscosity,Brookfield, No. 20 Spindle,20

1'.p.m cps., max.

at 400 F.

' Moreover, the'saturant rnust'be one that is compatible with theasphalt used in'the coating layers, the compatibility being determinedbythe Oliensis compatibility test run at room temperature. 7

The base may be saturated in a molten bath of asphalt of, theabove-mentioned properties maintained at a temperature in the range of400 to 475 F., the saturating step being conducted so as to saturate thebase with the asphalt in an amount of from 85%, preferably 110%,

' j to by weight.

the trade as-heavy goods. This material is a very strong fabric, whichwhen saturated and provided with the layers of filled asphalt coatingas, hereiridescribed, possesses a Mullen bursting strength greater than250 pounds per square inch, and a tensile strength in excess of 100pounds ('l"-l2/min.). Likewise, there may be employed a jute fabric of11 X 12 weave, weighing 12 ounces per lineal yard of 36 inch width.Although this latter fabric is slightly more costly than the heavierweight fabric of lower thread count first mentioned, and thefinishedproducts made from each of them are of substantially the samestrength, the lighter weight jute with the higher thread count is ofadvantage'in manufacture of the' liner material, in that it provides asmoother fabric base for saturation with asphalt andpermits'moreuniformlayers of'the stabilized asphalt coating to be applied. Also, itexhibits ditch liner when saturated and coated with the catalyticasphalt he'reindescribed, whereas these fabrics when coated withstraight b lown'asphaltshow numerous cracks which permit waterpermeation when a standing head of water is placed overfthe finishedmembrane sheet.

The. woven jute base may be 'rot-proofed by any conventionalmeans,utilizing mercury salts or copper salts as the active rot-proofingagent. Thus, for example, the base may be treated with a solution ofcopper naphth'enate -in mineralspirits, by immersing the fabric in thesolution. 7

Desirably, the solution is of such concentration and the durationofimmersionshould be suerrthat'after evaporation of the mineral spirits,an amount of the copper-cornpound in the range from 0.5 to l.0 expressedas copper,

will be provided in-order to impart adequate protection against decayorganisms. Alternatively, theba'se maybe treated with cuprammoni umsolutions to provide a similar quantity of copper. In lieu of coppersalts, there may be i The asphalt for the coating layer is, as abovesetforth, as asphalt. air-blownrin the presence of one of thephosphorus'compounds above-mentioned as. catalyst, and ex hibiting thefollowing physical properties:

Softening point, Ring and Ball -210 F. Penetration at:

77 F., 100 g./5 sec., mml/lO 43-53.

32 F., 200 g./60 see, mm./l0 30 min.

115 F., 50 g./5 sec., mm./l0 100 maX. Flash point, Cleveland 00 .4 475F. min Ductility at 77? F., 5 cm. per minute,

min. 3 /2 cm.

As above indicated, this coating asphalt is stabilized with finelydivided mineral, such as traprock, of a grading such that 90% passes a100 mesh sieve, the quantity therei of admixed with the asphalt being inthe range of from 25 to 45% by weight of the asphalt.

The stabilized asphalt coating may be applied to the oppositefaces ofthe saturated base in any convenient fashiomwhile at a temperature inthe range of from 275 to 350 F. The amount of coating material applied,pref- 'erably in layers of substantially equal thickness on both faces,should be such as to provide, together with the mineral surfacingsubsequently applied thereover, a comin those instances where thematerial is'to be furnished for use: as" an exposed membraneunderconditions requiring increased weather resistance.

As will be understooifthe steps of rot-proofing, saturating, coating andsurfacing the base ofwoven jute fiber will be most economicallyconducted on continuously running sheets of the base. The finished sheetmay be employed mercurysalts of limited water solubility'and which canbe selectively absorbed on the fibers. 7

After treatment with the rot-proofing solution, the

' woven jute base is saturated with' iasphalt by running it through abath of the asphalt saturantl The asphalt 'satur'ant is preferably anair-blown, steam and vacuum reduced asphalt having a softening point;

wound up in convoluted rolls of convenient size, using a suitablydimensioned core on a mandrel Winder. Preferably' informing each'woundup roll, the leading edge of the sheet is stapled to the core andreverse wound, i.e with the' mineral surfaced side facing outwardly. 7In the-following tabulation are'f set forth data with re,- specttothephysical properties'and amounts of the com-- 5 ponents making upthree forms of liner material em bodying the invention.

viscosity, and ductility as above set forth.

Catalytic air-blown, softening point 194 (R. & 13,), penetration, flashpoint, and ductility as above set forth.

Coating: Asphalt Stabilizer Traprock, 90% passing 200 mesh.

Surfacing N o. 11 roof- Talc No. 11 roofing granules ing granulesWfiight, pounds per 100 sq. 'J'ute base (including rot-proofing agent)8. 3 8.3 10. 4 t t 12. 5 12. 5 15.6 41. 3 75. 2 32. 4 30. 5 4. 28. Sand(selvedge edge)"- 0.3 (2) 0. 6 (4") Total 92. 9 100. 0 87. 5

In the accompanying drawing:

FIGS. 1, 2 and 3 are views depicting the sheets of liner material madeaccording to the data in columns A, B and C, respectively, of the abovetabulation, these views being taken transversely of the sheets;

FIG. 4 is a view, in perspective, illustrating a canal or the like,lined with sheet material made according to the invention; and

FIG. 5 is an enlarged detail view.

In FIGS. 1 and 2, the woven jute base referred to in columns A and B ofthe tabulation is indicated by numeral 10. In FIG. 3, the relativelyheavier base of lower thread count referred to in column C of thetabulation is indicated by numeral 20. In each instance, the jute baseis one that has been treated to render it rot-proof and to saturate itwith asphalt as above described.

The layers of mineral stabilized catalytic asphalt coating abovedescribed are at 12. In FIGS. 1 and 3, the layer of mineral granules assurfacing for the top face or" the sheet is indicated at 13, theselvedge edge of relatively fine sand is indicated at 14, and thesurfacing of mica or talc on the bottom face is indicated at 15. In FIG.2, depicting the relatively smooth surface liner material, the surfacinglayer of mica or talc is indicated by reference numeral 16.

In applying the material for lining the canals or ditches of irrigationor water conservation systems, the material in sheets of convenientwidth, preferably thirty-six inches, is supplied in the form ofconvoluted rolls to the job site. There it may readily be unrolled andcut into sheets of desired or required length.

Referring to FIG. 4, the sheets 25 are placed cross-wise in the canal orditch 30, and with an excess at the ends 31 thereof extending alongopposite sides of the canal or ditch so as to project out over the berms32 and later to be covered with earth.

As will be understood, the surface of the ditch will have previouslybeen compacted as by a vibratory com-.

pactor, and the berm will have been compacted as by the tread of a cattractor such as used in pulling the ditchdigging apparatus.

As indicated in FIG. 4, the pre-cut sheets are placed so as to overlapone another a distance of about two inches, the overlap, as shown inFIG. 5, extending in the direction of the flow of water. At theoverlaps, the sheets are joined and sealed to one another, preferably byheat, such as may be obtained from a propane torch applied to the marginof a sheet previously placed and the margin of the next overlappingsheet (rolled back sufficiently for the purpose) until the asphalt onboth becomes molten. Thereupon these marginal portions are placed incontact with one another.

If desired, instead of joining the sheets as they are being placed inthe canal or ditch, a convenient number of them, say six, may be joinedin the overlapping relation on the ditch shoulder, and the thus joinedassembly moved as a unit over and into place in the canal or ditch.

Where the sheets are of the smooth surface variety, a weather-resistantsurface coating, preferably comprising a clay-type aqueous emulsion ofasphalt of to F. melting point, and with or without an admixture of sandor the like, may desirably be sprayed or otherwise applied thereover.

The end portions of the sheets, extending over the berms 32 may be helddown temporarily in any convenient fashion, until a desired length ofthe canal or ditch has been lined in the manner described, and untilthey are covered by the soil applied over the berms.

What is claimed is:

1. Flexible sheet material forlining canals and ditches, comprising awoven jute fiber base of from 5 x 8 to 11 x 12 thread count and weighingfrom 7 to 15 ounces per lineal yard of forty inches width, said basecontaining an effective amount of a rot-proofing compound and beingsaturated, in an amount of from 85% to by weight thereof, with asphalthaving a softening point (R. & B.) of 135 to F., and a layer ofasphaltic coating on each face of the thus saturated base, said coatingconsisting essentially of (1) an asphalt air-blown in the presence of acatalyst selected from the group consisting of phosphorous pentoxide,red phosphorous, stable phosphorous sulfides and phosphoric acid, and(2) from about 25 to 45% by weight of finely divided mineral particlesat least 90% of which pass a 200 mesh sieve, said catalyticallyair-blown asphalt being characterized by a ductility of not less than3.5 centimeters at 77 F. (5 centimeters per minute), a softening point(R. & B.) of to 210 F., and a pene t'ration of about 43 to 53 at 77 F.(100 g./5 sec.,

mm./l0), said coating layers each having a layer of mineral surfacingmaterial applied thereover.

2. Sheet material as defined in claim 1, wherein th layer of mineralsurfacing material applied over each of said coating layers is talc. J

3. Sheet material as defined in claim 1, wherein the layer of mineralsurfacing material applied over the coating layer on one face is talc,and the surfacing material applied over the coating layer on the otherface comprises mineral granules graded in size to pass an 8 mesh sieveand be retained on a 35 mesh sieve.

4. Sheet material as defined in claim 3, wherein said surfacing ofmineral granules extends over the full width of the sheet except for arelatively narrow selvedge along one edge of the sheet, and wherein saidselvedge is surfaced with a layer of finely divided sand.

5. Sheet material as defined in claim 1, wherein the combined weight ofsaid coating'and mineral surfacing layers constitutes from about 70% toabout 80% of the total weight of the sheet material per unit area.

6. Sheet material as defined in claim 1, wherein said 7. Sheet materialas defined in claim 1, further characterized by a Mullen burstingstrength of at least about 250 pounds per square inch.

- width, andwherein the layer of mineral surfacing material applied overeach of said coating layers is talc.

9. Sheet material as defined in claim 7, wherein said woven base has athread count of 11 X 12 and weighs approximately 12 ounces per linealyard of 40 inches width, and wherein the layer of mineral surfacingmaterial applied over the coating layer on one face is talc, and thesurfacing material applied over the coating layer on the other facecomprises mineral granules graded in size to pass an 81mesh sieve and beretained on a 35 mesh sieve.

10. Sheet material as defined in'claim 7, wherein said,

woven base has a thread count of 5 x 8 and weighs approximately 15ounces per lineal yard of, 40 inches width, and wherein the layer ofmineral surfacing material applied over the coating layer on one face istalc, and the surfacing material applied over the coating layer ,on theother face comprises mineral granules graded in size to pass an 8meshsieve and be retained on mesh sieve.

References Cited in the file of this patent UNITED STATES'VPATENTSFinley Apr. 24, Overbury Mar. 25, Rahr May 27, Kirschbraun June 24,Kirschbraun Sept. 23, Fordyce July 14, Kirschbraun I an. 4, Baker May 9,Greider et al. n. May 23, Swope Aug. 6, Burnet Apr. 25, 'Hoiberg Oct. 5,Baskin Feb. 13, Bramble Nov. 27, Oldfield July 2,

1. FLEXIBLE SHEET MATERIAL FOR LINING CANALS AND DITCHES, COMPRISING AWOVEN JUTE FIBER BASE OF FROM 5X8 TO 11X12 THREAD COUNT AND WEIGHTINGFROM 7 TO 15 OUNCES PER LINEAL YARD OF FORTY INCHES WIDTH, SAID BASECONTAINING AN EFFECTIVE AMOUNT OF ROT-PROOFING COMPOUND AND BEINGSATURATED, IN AN AMOUNT OF FROM 85% TO 150% BY WEIGHT THEREOF, WITHALPHALT HAVING A SOFTENING POINT (R.&B.) OF 135 TO 160*F., AND A LAYEROF ASPHALTIC COATING ON EACH FACE OT THE THUS SATURATED BASE, SAIDCOATING CONSISTING ESSENTIALLY OF (1) AN ASPHALT AIR-BLOWN IN THEPRESENCE OF A CATALYST SELECTED FROM THE GROUP CONSISTING OF PHOSPHOROUSPENTOXIDE, RED PHOSPHOROUS, STABLE PHOSPHOROUS SULFIDES AND PHOSPHORICACID, AND (2) FROM ABOUT 2K TO 45% BY WEIGHT OF FINELY DIVIDED MINERALPARTICLES AT LEAST 90% OF WHICH PASS A 200 MESH SIEVE, SAIDCATALYTICALLY AIR-BLOWN ASPHALT BEING CHARACTERIZED BY A DUCTILITY OFNOT LESS THAN 3.5 CENTIMETERS AT 77*V. (5CENTIMETERS PER MINUTE), ASOFETNING POINT (R.&B.) OF 190 TO 210*F., AND A PENETRATION OF ABOUT 43TO 53 AT 77*F. (100G./5 SEC., MM./10), SAID COATING LAYERS EACH HAVING ALAYER OF MINERAL SURFACING MATERIAL APPLIED THEREOVER.